S2 JPS project

[LOTUSMAN33]

Dilemma...

Talking to Steve at SJ today he thinks I would be absolutely mad to remove the air system/pump and Cat Exhaust as said he’s never actually seen an Esprit with it fitted other than a picture which considering he must have worked on endless Esprit over the past 44 years is making me think...

Not really worried about performance too much otherwise I would have bought a turbo or later variant but it does mean the euro rear valance won’t fit unless I pay out £600 for a euro stainless exhaust.

Steve said he can do me an extended US valance with grille which fits the euro rear bumper.

Clearly lots of work went into this system as the head is different to accept the air injectors and the exhaust is smart with excellent heat shields. 
I spoke to Andy Graham after and he was the same having not seen one.

SJ Euro kit for the S2

Euro valance and stainless exhaust which is bling!

I could run the Air system with the above I guess and retain my original bits but I do quite like the quality of the OEM system fitted.

If you run a euro bumper with the US valance you need to sit the bumper lower on the car.

With Steve’s extended federal valance you can have the bumper at standard height.

Or bite the bullet and buy the exhaust, mount plates, straps and fixing losing the CAT going full euro spec

Opinions? 🤞🏼👍🏻

Dave  

 

[Barrykearley]

There’s a reason behind him never seeing one with it on 👍

[Fridge]

From a design point of view if going Euro you have to position the rear bumper where it's meant to be. Without the gap, otherwise it looks a bit rubbish.

As for converting to Euro carburetion that'll depend upon your intentions. Personal use, your choice perhaps keep original, but changing the bumpers is moving away from that anyway. Flip to Europe, then Del'lortos are the only way IMO, otherwise you're limiting its appeal.

If you want to fit new Federal bumpers to retain all originality then contact Bill Galbraith in Florida who has remade them.

[LOTUSMAN33]

I think you’re right David, I’ve been reading up on US sites about the dieseling effect the air pumps had with up to 10 secs of overrun along with the air flow restriction the actual air injectors make.

I’m going to remove and machine up some plugs for the head but retain all the emissions equipment in my loft in case ever needed again.

So a shiny new exhaust it is, I think I will need a different adapter plate on the rear of the gearbox, different mount and straps alike so not a cheap exchange.

I’m thinking about rebuilding the DHLA 48 carbs I have as they are in superb condition and seeing how they run on the 907, I will have to set them up carefully which is fine but they were fitted prior to the current Webber’s.

If it doesn’t work out I will sell them and get some 45 carbs instead.

As for the valance, I would not have entertained dropping the bumper as reminds me of a teenager with his jeans half way up his ass 😁

Dave  

[drdoom]

The Federal spec was a miserable affliction, not something to cherish in my opinion. Set the car up as the design team would have preferred it and stash away the smog bits for your own peace of mind Nothing trick about the air pump port plugs, they are very likely 1/8 NPT or similar tapered thread.

[Fridge]

If you decide that you don't want the anti-smog equipment I know someone who may buy it.

[LOTUSMAN33]

Thanks David, to make it of any use would require the head as well I believe for the air injectors to be installed unless a standard head can be modified.

[Fridge]

The owner may have those. I've sent them a link to this thread in case it's mutually beneficial to transact.

[Final Edition]

Thanks for directing me to this thread @Fridge !

Hi @LOTUSMAN33 , hijacking the thread a bit to show my 1977 S1, I picked it up last weekend. An original Monaco white car with 31,000 miles on the clock.

I have managed to locate an air pump and injectors stateside but let me know if you'd like to sell your federal parts. I'm based in California so have to pass SMOG emissions to get it registered here. My car has Weber carbs, I've just bought a pair of Stombergs that will have to go on, bye bye 20 bhp!

You can see the air injectors in my pix plugged up. A previous owner took off the air injector rail and air pump. Catalytic converter remains. I'll start a separate build thread when I get it spruced up.

 

[LOTUSMAN33]

Nice find, I will have a think about what I want to do with the kit as did plan to keep it with the car TBH.

I do understand the need and how challenging it is finding these used parts especially when required for the California smog test.

Dave  

[v8vantage]

Keep all the original pieces, keeps the value if you ever sell and the new owner wants to return to original. Fit the SJ rear bumper and extended valance but keep the original exhaust. Remove air pumps and piping, easy to fit bungs to the head to block the holes. My car has had this done and runs fine. Do not swap the head with anyone, it's only original once.

[LOTUSMAN33]

Thanks Roo, this has been a proper dilemma, SJ gave the same advice keeping it as was or retaining parts doing himself out of around £800 for an exhaust system. 

The exhaust is in fantastic condition only really needing the two silencer heat shields replaced which Steve sells. I actually like the look of the system with mesh guards as well.

Funny enough I was adamant I would fit my two alloy tanks but these tanks are rot free so going to stick with the originals just changing the hosing.

Dave  

 

 

[LOTUSMAN33]

So some progress although been pretty busy doing DIY keeping the boss happy 😊 

Interior dropped off at the trimmers today to have the leather replaced where required, great bunch of people who are very knowledgeable about the Esprit and their interiors from Tartan to the Essex so I feel in very safe hands.

Fitted the euro front lights today into the bumper and wired up with side lights now, the federal Esprit is very different from a U.K. car wIth an extra panel behind the front which is then foam filled in the void so a fair bit of cutting was required to accept the clubman lights which was time consuming. I added the rubber trim which was missing so fit is far better now. Just needs its reg plate next 😁

I have had to order different headlight bowls as these wouldn’t take the new lights due to the lug positions being way out.

Next job will be degrease the engine and glassfibre the original US tag panel to fit the UK plinth, I will remove the rear marker lights at the same time and fill all the bumper holes etc from the impact bumpers.

Dave  

 

[Guest]

JAE has the plugs for the air injector ports. Rather than just plugging the injector, with theirs you remove the injector and plug the threaded port in the head. 

I hardly think my S1 ‘ looks a bit rubbish’. 

 

[LOTUSMAN33]

Thanks Gavin that’s very helpful, I will see if I can find them on their website.

I didn’t realise that was your yellow S1 as just a google library image. I certainly never called a S1 rubbish as a big fan especially yellow/tartan as a combo👍

Dave  

[Guest]

Your all good Dave....it was Fridge that thinks it looks a bit rubbish from the arse.

Enjoying the thread!

[Fridge]

@gtookey I think it looks better if the gap between the top of the rear bumper and the waistline trim is the same as on Euro spec cars.

I'd have to check back on that photo, but I suspect that the distance been the exhaust pipes to the underside of the bumper is also increased. Design-wise, it's an interesting area, and even more pronounced on cars like the De Tomasa Pantera.

SJ Sportscars now make a rear valance for catalyst cars which I "ass-ume" is deeper but extends further. Allowing the bumper to be mounted higher.

Like @LOTUSMAN33 I'm not sure if I like the rear valance with the lower grill or not. The Euro version is certainly neater, but in some ways the grill and visible exhaust muffler reminds me of certain Muiras etc. Something hardly ever seen on today's jelly mould commuters, which seem to hide every ounce of machinery.

SJ's parts are good quality, but I think their supplier isn't up to full speed, and deliveries to the US are taking a lot longer than normal due to reduced air freight schedules.

[LOTUSMAN33]

A little more progress, I removed the Federal parts this weekend starting with the marker lights then rear valance and bumper followed by license plate holder.

 

I then removed the Air Pump so thought I would remove the exhaust to give better access to the Air Injectors which was a wise choice.....

What was wedged in the silencer, still more in there and what’s left in the Catalytic converter is loose, this must have killed the cars performance and may be the reason for being taken off the road?

The engine bay looks much neater without the Air pump, still a few bits to remove but access will be tough going.

I also started to degrease the engine and box, the gearbox end cover is leaking as is the selector shaft so glad I removed the exhaust which will now be replaced with a Peco stainless sports system.

I have also started to fibreglass the marker light holes and number plate aperture ready the the UK plate holder.

The original Title arrived in the post Saturday and I’ve order a provenance certificate from Andy Graham in readiness for getting it registered once the NOVA certificate arrives.

I’ve run out of degreaser so will grab some during the week and finish the clean up then start work on the mechanics, I have a feeling the cam box may be leaking so in two minds about just pulling the engine and do a good seal change but really want to run it first in case anything more needs sorting out so will do the easy stuff now.

Drain the fuel tanks next, change the pump and hoses then timing belt, rather unbelievably the Air Con system still has loads of pressure in it! 

I think the oil cooler is weeping oil so may just fit a new one when I do the service for peace of mind?

Working on the car has been a pleasure so for will everything being greased and coming apart easily including the exhaust, not had to go for penetrating oil yet so a big bonus 😁

Dave  

 

[Lotusfab]

Looks in good nick Dave!

[v8vantage]

If you drain your tanks try and derust them with this: https://www.amazon.com/Evapo-Rust-Original-Water-based-Non-Toxic-Biodegradable/dp/B00370N1UG I let it sit for a week then drain and flush out with water and then dry with air hose. Look like new inside. I also use it in my ultrasonic cleaner to derust nuts/bolts/parts before re plating them.

[LOTUSMAN33]

Thanks Roo, I will get some of that although couldn’t see any rust with my RVI camera only about 1/8-1/4 of fuel in each which was quite smelly. 
I do have a pair of alloy tanks already but will keep these for the future I think.

Dave  

38 minutes ago, Lotusfab said:

Looks in good nick Dave!

Yes really pleased Fabian, only rust is surface where paint coatings have been broken from jacks etc. I will rub these down and represerve as I work on various bits. 👍

Dave  

[LOTUSMAN33]

A little more progress with all the fibreglassing now done and into body prep, the main areas to get paint will be the rear end where a large hole was left from the US plate holder, both capping rails, new rear spoiler and where the four marker lights were below the waistline.

Big hole to fix as don’t want to run around with a small number plate in the recess, I’ve ordered a S2 plate holder which should be here soon. I’ve also ordered a Stainless Peco sports exhaust.

Release film added

Secured with OSB to keep a nice flat repair, there is a slight curve to the panel which will be recreated with high quality filler.

Part way through fibreglassing the rear after applying black gel coat to the release film first.

OSB removed, looking pretty good and very strong

Front ground out for a layer of fibreglass to close the join completely.

Fibreglass applied which is then followed by Gel Coat filler after sanding back (forgot to photograph that bit).

Now all filled using Durablocks ready for high build primer and guide coating, it feels very good by eye and passed the straight edge and light check.

Remove lights next to prep the whole panel then the fun bit! Looking forward to getting the UK rear bumper and trial fitting before going to paint as may have to do some repairs below the rear waistline yet.

The marker lights have had similar treatment although access to the fronts has been a pig with the extra crash panel the federal cars get.

A little more prep and they will be ready for paint as well.

I’m saving the mechanical work for the winter months doing the warm weather only stuff now which is killing me as dying to get stuck in and running her up 😁
 

I think one day I will get the whole car painted but enjoying lots of small smart repairs at the moment and even did a leather repair on a small area which is now nearly invisible before polishing the remaining leather work.

Dave  

 

 

[LOTUSMAN33]

 My radio parts arrived today to fix the missing flap and search button on the original Blaupunkt radio, after a service and head clean this evening all is working well so time to go up the loft and dig out the old tapes 😁

Really pleased, now just awaiting the centre console to come back from the trimmers following some heating up and straightening so I can properly install with a new aerial.

Provenance certificate draft came on email as well today which shows it being 1 of 22 California spec cars and 1 of 55 federal built cars for the US and Canada.

Dave  

 

[jep]

Almost as exciting as the thread on S1 ashtray. 

Who did the flap for you or was it second-hand original? 

Justin 

Have all my tapes to hand and use in Excel regularly.

Justin  

[LOTUSMAN33]

Lol some true 80’s pop icons there Justin, mine are pretty similar with a few early ‘Now’ albums as well. 🍻
I bought a broken stereo from Italy from a Ferrari 308 for the bits.

I love the details hence the S1 ashtrays etc, a bit of a geek I guess 🤣

Dave